2008 Kawasaki KLR650 Maintenance Schedule and Service Intervals

This is the maintenance schedule and associated service intervals for the 2008 Kawasaki KLR650.

The Kawasaki KLR650 is a dual-sport motorcycle intended for both on-road and off-road riding.

It was a long-standing model in Kawasaki’s lineup, having been introduced in 1987 and remaining almost unchanged through the 2007 model. The 2008 model was the first significant redesign of the KLR650 since its inception. It was built with a 651 cc four-stroke, DOHC, dual-counterbalanced, single-cylinder, water-cooled engine.

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2008 Kawasaki KLR650 Maintenance Schedule

Below is the maintenance schedule for the 2008 Kawasaki KLR650.

The maintenance for the 2008 Kawasaki KLR650 is broken into three sections: Engine Related Items, Chassis Related Items, and Change/Replacement items.

The maintenance for the 2008 Kawasaki KLR650 shall be carried out whichever comes first.

Periodic Maintenance Chart

	1. Periodic inspection (Engine Related Items) Operation (Engine Item)	Every	1000 km (600 mi)	6000 km (4000 mi)	12000 km (7500 mi)	18000 km (12000 mi)	24000 km (15000 mi)	30000 km (20000 mi)	36000 km (24000 mi)
	Air cleaner element – clean(e)				•		•		•
	Valve clearance – inspect (e)						•
	Throttle control system (play, smooth return, no drag) – inspect (e)	year	•		•		•		•
	Choke operation – inspect (e)	year	•		•		•		•
	Idle speed – inspect (e)		•		•		•		•
	Fuel leak (fuel hose and pipe) – inspect	year	•		•		•		•
	Fuel hoses damage – inspect	year	•		•		•		•
	Fuel hoses installation condition – inspect	year	•		•		•		•
	Coolant level – inspect		•		•		•		•
	Coolant leak – inspect	year	•		•		•		•
	Radiator hose damage – inspect	year	•		•		•		•
	Radiator hoses installation – inspect	year	•		•		•		•
	Evaporative emission control system – function (California model only) (e)		•	•	•	•	•	•	•
	Air suction system damage – inspect (e)				•		•		•
	2. Periodic Inspection (Chassis Related Items) Operation (Chassis Items) Clutch and drive train:
	Clutch operation (play, engagement, disengagement) – inspect		•		•		•		•
	Drive chain lubrication condition – inspect #	every 600 km (400 mile)
	Drive chain slack – inspect #	every 1000 km (600 mile)
	Drive chain wear – inspect #				•		•		•
K	Drive chain guide wear – inspect				•		•		•
	Wheels and Tires
	Tire air pressure – inspect	year			•		•		•
	Wheels/tires damage – inspect				•		•		•
	Tire tread wear, abnormal wear – inspect				•		•		•
K	Wheel bearings damage – inspect	year			•		•		•
K	Spoke tightness and rim runout -inspect		•	•	•	•	•	•	•
	Brake system
	Brake fluid leak – inspect	year	•	•	•	•	•	•	•
	Brake hoses damage – inspect	year	•	•	•	•	•	•	•
	Brake pad wear – inspect #			•	•	•	•	•	•
	Brake hose installation condition – inspect	year	•	•	•	•	•	•	•
	Brake fluid level – inspect	6 month	•	•	•	•	•	•	•
	Brake operation (effectiveness, play, drag) – inspect	year	•	•	•	•	•	•	•
	Brake light switch operation – inspect		•	•	•	•	•	•	•
	Suspensions
K	Front forks/rear shock absorber operation (damping and smooth stroke) – inspect				•		•		•
K	Front forks/rear shock absorber oil leak – inspect	year			•		•		•
K	Uni-trak rocker arm bearings – lubricate						•
K	Uni-trak rocker arm operation – inspect				•		•		•
K	Uni-trak tie rods operation – inspect				•		•		•
K	Uni-trak tie rods bearings – lubricate						•
K	Swing arm pivot – lubricate						•
	Steering system
K	Steering play – inspect	year	•		•		•		•
K	Steering stem bearings – lubricate	2 years
	Electrical system
	Light and switches operation – inspect	year			•		•		•
	Headlight aiming – inspect	year			•		•		•
	Side stand switch operation – inspect	year			•		•		•
	Engine stop switch operation -inspect	year			•		•		•
	Battery electrolyte level – inspect	6 months	•	•	•	•	•	•	•
	Chassis:
	Chassis parts – lubricate	year			•		•		•
	Bolts and nuts tightness – inspect		•		•		•		•

	3 Periodic Replacement Change/Replacement items	Every	1000 km (600 mi)	12000 km (7500 mi)	24000 km (15000 mi)	36000 km (24000 mi)	48000 km (30000 mi)
	Air cleaner element #(e)	2 year
	Engine oil #	year	•	•	•	•	•
	Oil filter	year	•	•	•	•	•
K	Fuel hoses	4 years					•
K	Coolant	3 years				•
K	Radiator hoses and O-rings	3 years				•
K	Brake hoses	4 years					•
K	Brake fluid (front and rear)	2 years			•		•
K	Rubber parts of master cylinder and caliper	4 years					•
	Spark plug (e)			•	•	•	•

K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
(e) Emission Related Item

Tyre size and tyre pressure for the 2008 Kawasaki KLR650

The 2008 Kawasaki KLR650 has the following tyres and tyre sizes standard:

Front: Dunlop 90/90-21 M/C 54S K750
Rear: Dunlop 130/80-17 M/C 65S K750

The manual for the 2008 Kawasaki KLR650 recommends the following tyre pressures (when cold):

Front: 150 kPa/21 psi
Rear (up to 97.5 kg/215 lb load): 150 kPa/21 psi
Rear (over 97.5 kg/215 lb load): 200 kPa/28 psi

About the 2008 Kawasaki KLR650

The KLR650 has all new 41mm front forks now have less static sag for a taut, smooth ride on pavement. Front suspension travel is reduced from 9.1 in. to 7.9 in. A redesigned UNI-TRAK linkage reduces sag and compliments the new front suspension by reducing rear wheel travel from 8.1 in. to 7.3 in.

The 2008 KLR650 features enhanced stopping power, thanks to a new 280mm petal-style front brake rotor that’s similar to ones used on Kawasaki’s Ninja sportbikes. Fitted with a lightweight and thin cooling fan, the new radiator has a greater cooling area and offers a 20% increase in cooling efficiency.

Simplifies maintenance by providing better access to the rear shock, airbox, and carburetor large rear cargo rack included. Rear braking performance is also improved, thanks to a new rear brake caliper. This new suspension and brake upgrades boost the KLR650’s on-road performance, without diminishing its versatile off-road capabilities.